Methods of embroidery, and products so made

ABSTRACT

New methods of providing embroidered indicia on patches which are mounted to articles of manufacture. After the patch is mounted to a substrate which is a functional element of the article of manufacture, the patch is embroidered to provide the embroidered indicia. Embroidering on the patch after the patch is mounted to the substrate passes the embroidering threads through both the patch and the substrate, such that the embroidery threads provide at least supplemental, optionally primary, attachment of the patch to the substrate. The substrate, thus the corresponding product, can be, without limitation, a piece of wearing apparel, namely a garment. Any product which is susceptible of receiving an embroidered patch is susceptible of benefiting from the methods of the invention, along with the corresponding resultant inventive products.

BACKGROUND

This invention relates to embroidered garments and other wearingapparel. Such garments and other wearing apparel, hereinaftercollectively referred to as garments, include for example and withoutlimitation, shirts, T-shirts, sweat shirts, caps, shop shirts or workshirts (hereinafter referred to as work shirts), bowling shirts,jackets, pants, and the like.

Embroidered garments have become increasingly common, and increasinglymore popular. Demand for embroidered garments has resulted inintroduction of a wide variety of embroidered products. Such productsinclude those where embroidered indicia are defined directly on thegarment as well as those where the embroidered indicia are defined on apatch which is attached to or affixed to the garment.

Specifically, this invention relates to embroidered garments wherein theembroidered indicia are defined on a patch, or patches, which is/areapplied to the garment.

It is known to apply embroidery indicia to a patch, and to subsequentlyaffix the patch to the garment. The patch may be affixed by stitchingabout the outer perimeter of the patch, or may be attached by adhesiveon a surface of the patch or garment between the patch and the garment,or both.

SUMMARY

This invention provides new methods of providing embroidered indicia ongarments and other articles of manufacture where a patch is used as acarrier of the embroidered indicia. The patch is mounted to a substratewhich is a functional element of the article of manufacture, and issubsequently embroidered to provide the embroidered indicia. Theembroidering on the patch which occurs after the patch is mounted to thesubstrate passes the embroidering threads through both the patch and thesubstrate, such that the embroidery threads provide at leastsupplemental attachment, and in some embodiments primary attachment, ofthe patch to the substrate. In some embodiments, the substrate, and thusthe corresponding product, is a piece of wearing apparel, namely agarment. In other embodiments, the substrate embodies some or all of anon-garment product, such as a decorative pillow, a cushion, a blanket,or other household product. Any product which is susceptible ofreceiving an embroidered patch is susceptible of benefiting from themethods of the invention, along with the corresponding resultantinventive products.

In a first family of embodiments, the invention comprehends, incombination, a patch, and a garment to which the patch is mounted. Thepatch comprises a first outer surface facing away from the garment, afirst inner surface facing toward the garment, a perimeter which definesan outer edge of the patch, and an outer edge region disposed proximatethe outer edge of the patch. The garment has a second outer surfacefacing away from the garment, including toward the patch, and a secondinner surface facing inwardly, toward a body of a wearer of the garment.The combination of the garment and the patch comprises embroideredindicia on the outer surface of the patch. Threads defining theembroidered indicia extend through both the patch and the garment.

In some embodiments, the combination further comprises a layer ofadhesive between the patch and the garment. The threads defining theembroidered indicia further extend through the layer of adhesive.

In some embodiments, the layer of adhesive comprises heat seal adhesive,bonding the patch to the garment.

In other embodiments, the layer of adhesive comprises contact adhesivebonding the patch to the garment.

In still other embodiments, the layer of adhesive comprises a firstlayer of heat seal adhesive and a second layer of contact adhesive.

In some embodiments, the embroidered indicia is confined inwardly of theedge region of the patch.

In other embodiments, the embroidered indicia extends into the edgeregion of the patch.

In some embodiments, the embroidered indicia covers the entirety of theouter surface of the patch, including in the edge region.

In some embodiments, the embroidered indicia is predominantlyinformational in nature, for example letters, numbers, words, or thelike.

In other embodiments, the embroidered indicia is predominantly artisticin nature, for example natural or fanciful designs, objects, or thelike.

In still other embodiments, the embroidered indicia is a generallybalanced combination of informational and artistic elements.

In some embodiments, the combination further comprises stitching, eithersewing stitches or embroidery stitches, about the outer edge of thepatch, as supplemental securement of the outer edge of the patch to thegarment.

In some embodiments the combination comprises a cut-out aperture in thepatch material, disposed inwardly of the outer edge of the patch, and asecond edge region about the cut-out aperture, wherein the embroideredindicia may or may not be displaced from the second edge region.

In some embodiments, the patch is so affixed to the garment by theembroidered indicia that the patch cannot be removed from the garmentwithout damaging a substantial portion of the embroidered indicia on thepatch.

In a second family of embodiments, the invention comprehends a method ofmounting a patch to a garment. The method comprises, from a web of patchmaterial, cutting out a patch having a desired outline, the patch havingfirst and second opposing surfaces, and an outer perimeter defining anouter edge of the patch, and a corresponding outer edge region proximatethe outer edge; subsequent to cutting out the patch, mounting the patchto the garment; after mounting the patch to the garment, embroideringindicia onto the patch, including extending embroidering threads throughboth the patch material and through the garment.

In some embodiments, the method further comprises, prior to mounting thepatch to the garment, applying a layer of adhesive material to the patchso as to cover substantially the entirety of the first surface of thepatch, and activating the adhesive as necessary in the process ofmounting the patch to the garment, whereby the adhesive materialfacilitates the mounting of the patch to the garment.

In some embodiments wherein the layer of adhesive material comprises alayer of hot melt adhesive, the method further comprises heating the hotmelt adhesive in the process of mounting the patch to the garment, so asto activate the hot melt adhesive thereby to facilitate the mounting ofthe patch to the garment, and wherein the extending of the embroideringthreads through the patch material and through the garment furthercomprises extending the embroidering threads through the layer of hotmelt adhesive.

In some embodiments, the method includes defining a first portion of theembroidered indicia inwardly of the edge region, and a second portion ofthe embroidered indicia in the edge region.

In some embodiments, the patch further comprises a cut-out aperture inthe patch material, disposed inwardly of the outer edge, and a secondedge region about the cut-out aperture, the method further comprisingconfining the embroidered indicia away from the second edge region.

In some embodiments, the patch is so affixed to the garment by theembroidered indicia thereon, with or without the use of an interveninglayer of adhesive, that the patch cannot be removed from the garmentwithout (i) damaging a substantial portion of the embroidered indicia onthe patch.

In a third family of embodiments, the invention comprehends a method ofcreating a garment bearing an embroidered patch, the patch having firstand second opposing surfaces, an outer perimeter defining an outer edge,and an edge region proximate the outer edge. The method comprises atleast temporarily affixing the patch to the garment; subsequent to atleast temporarily affixing the patch to the garment, passing embroiderythreads through both the patch and the garment in developing embroideredindicia on the patch.

In some embodiments, the method includes, prior to passing embroiderythreads through both the patch and the garment, the at least temporarilyaffixing of the patch to the garment comprising affixing the patch tothe garment using an intervening layer of adhesive, optionally a layerof hot melt adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a pictorial view of a work shirt embodying informationalembroidery indicia of the invention, in the form of a person's nameembroidered on a patch, and the patch mounted on the shirt.

FIG. 2 shows an enlarged view of the patch area of the work shirt ofFIG. 1, including the embroidered patch.

FIG. 3 shows an enlarged view of a patch area of a garment, including anembroidered patch, as in FIG. 2, but showing the number “8”, embroideredwith fanciful graphic e.g. artistic representations.

FIG. 4 shows a cross-sectional view of an embroidered garment/patchcombination of the invention and is taken at 4-4 of FIG. 3.

FIG. 5 shows a cross-sectional view of a second embodiment of anembroidered garment/patch combination of the invention.

The invention is not limited in its application to the details ofconstruction or the arrangement of the components set forth in thefollowing description or illustrated in the drawings, such descriptionand drawings being by way of illustration and example only. Theinvention is capable of other embodiments and/or of being practiced orcarried out in various other ways. Also, it is to be understood that theterminology and phraseology employed herein is for purpose ofdescription and illustration and should not be regarded as limiting.Like reference numerals are used to indicate like components.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

As used herein, “embroidered indicia” and derivatives thereof mean apattern or design, such as lettering, or numbering, or wording, orgraphics, or stylized elements of lettering, or numbering, or wording orgraphics, which may be informational or artistic in nature, using anembroidery machine to apply well-known embroidery stitches and/orstitching techniques, other than at, or in addition to, edge stitchingwhich is commonly applied by a sewing machine.

As used herein, “edge stitching” means stitching at the edge of thepatch, without extending such stitching to any other layer to which thepatch may ultimately be affixed and which preserves the woven pattern ofthe patch material in the edge region of the patch by stitchingtechniques other than embroidery stitching.

Referring to FIG. 1, a work shirt 10 has a front 12, a back 14, and leftand right arms 16. A patch 18, bearing the name “BILL” is mounted to thefront of the work shirt.

Turning attention now to FIGS. 2 and 4, the patch 18 has an outersurface 20 which faces away from the shirt, and an inner surface 22which faces toward the shirt. The shirt has a second outer surface 24which faces away from a body of a person wearing the shirt, a portion ofwhich faces patch 18, and a second inner surface 26 which faces inwardlyof the shirt, and toward the body of a person wearing the shirt.

Patch 18 further has an outer perimeter 28 which defines the outer edge30 of the patch, a corresponding outer edge region 32 proximate theouter edge, and an interior region 34 defined inside edge region 32.Correspondingly, the entirety of the outer surface of the patch consistsof the combination of the edge region 32 and the interior region 34.

Edge region 32 includes any portion of the patch adjacent the edge whichincludes edge stitching 36 which may be used to consolidate or preservethe woven pattern of the patch material at or adjacent the outer edge.The interior region of the patch is the remainder of outer surface 20which is not occupied by the edge region.

The edge stitching 36 can have a functional feature of preserving thewoven pattern of the patch material. Edge stitching 36 can be merelydecorative. Edge stitching 36 can be in part functional in preservingthe woven pattern and in part decorative. Edge stitching 36 is commonlya simple embroidery satin stitch which progresses in a regular andconsistent pattern about the edge of the patch. In the alternative, edgestitching 36 can be any embroidery stitch, or combination of embroiderystitches, in a regular or fanciful pattern, which performs any desirededge function, including consolidating, preserving and/or strengtheningstructure of the edge region of the patch material, enhancing theappearance of the edge of the patch, or participating in a largerpattern of embroidery indicia which extends inwardly of the edge region,conversely extends outwardly from the interior region to the edgeregion, including bridging the interior region and the edge region.

In the embodiment of FIGS. 1 and 2, interior region 34, is embroideredwith indicia 38 in the form of the word “BILL”, a person's name.

FIG. 3 shows a second enlarged view of a patch of the invention in theform of a number “8”. FIG. 3 illustrates at least two features which aredifferent from the embodiment of FIGS. 1 and 2. First, the embroideredindicia 38 are artistic and fanciful, rather than representing lettersor numbers, which are generally considered informational. Stylizedletters and numbers can be both informational and artistic. Further,graphic representations can be informational as well as artistic.Second, the configuration of patch 18 includes interior cut-outapertures 40, disposed inward of the outer region, in the interiorregion of the patch.

As with the edge stitching 36 at outer edge 32, the edges of apertures40 are optionally stitched with edge stitching, which can be employedfor he same reasons as the edge stitching 36 at outer edge 30.

FIG. 4 shows a cross-section of the patch 18 of FIG. 3, minus the edgestitching, and is also well illustrative of the patch of FIGS. 1 and 2.Edge stitching is not shown in FIG. 4 in order to emphasize otherfeatures of the figure, and in light of the fact that edge stitching inconventionally-embroidered patches is well known. As seen in FIG. 4, thecross-section includes a first layer 42 of the shirt material, a secondlayer 44 of the patch material, and an intervening layer 46 of adhesivematerial between the patch material and the shirt material.

The shirt material can be any shirt material which is known for use inshirts, as well as a wide variety of other materials which can be usedin fabricating other types of garments and/or other embroideredproducts. Thus, there can be mentioned a wide variety of woven andnon-woven sheet materials, reticulated and apertured materials which aresufficiently continuous in nature, and sufficiently dimensionallystable, to accept and hold the embroidery threads, and tocorrespondingly hold a stable representation of the indicia embroideredthereonto. The garment material can, further, be comprised of aplurality of layers, where all the layers can be the same, or can bedifferent materials and/or different structures based on the samematerial. Thus, the garment material or other substrate can be amultiple layer structure. The layers can be bonded to each other, ornot, depending on the properties desired for the particular garmentmaterial.

Typical patch material, also well known in the industry, is relativelystiff, and resistant to flexing, compared to typical shirt material orother garment material, and may be, for example and without limitation,a twill, a cotton, a polyester, or felt. The patch material can be, byway of further example, a polymeric film apertured, reticulated, or thelike. Thus, the patch material can be a multiple layer structure. Thelayers can be bonded to each other, or not, depending on the propertiesdesired for the particular patch material.

However, the patch material need not be stiff or resistant to flexing,as a wide variety of backing and other materials are well known forenhancing the stiffness of a patch where enhanced stiffness isdesirable. Accordingly, a wide range of patch materials can be used,including but not limited to any material which is otherwise known asbeing useful in making conventional patches and conventionally-patchedgarments.

Adhesive 46 can be any adhesive known for use in attaching patches togarments, either temporarily or permanently. As will be seen herein, atemporary affixation is, in some embodiments, all that is required ofadhesive 46. In other embodiments, the adhesive desirably is theprinciple functionary for permanently affixing the patch to the garment.

Adhesive 46 can be a contact adhesive, for example, a pressure-sensitiveadhesive. In the alternative, adhesive 46 can be a polymeric hot meltadhesive. The adhesive can be applied in any known manner includingspray application, and various other known coating process. The adhesivelayer can be either continuous, e.g. a full-surface sheet-like layer, ordiscontinuous such as spaced dots, or a connected continuous patternwhich embodies apertures and/or voids over a substantial portion of thearea defined by the pattern, or may be continuous over a first part ofthe coated surface and discontinuous over a second part of the coatedsurface.

Exemplary but not limiting of pressure sensitive and/or contactadhesives are acrylic esters, silicone resins, polyurethane dispersions,ethylene vinyl acetate, and rubber solvent blends. Respective ones ofthe above compositions can be homopolymers or copolymers, as well knownin the art.

Exemplary but not limiting of the hot melt adhesives are polyurethanes,polyamides, polyesters, polyethylenes, polyvinyl acetates, polyolefins,polyvinyl chlorides, ethylene-vinyl acetate copolymers, polypropylenes,and blends and other mixtures of the above compositions. Respective onesof the above hot melt compositions can be homopolymers or copolymers, aswell known in the art.

The amount of pressure sensitive adhesive applied varies depending onthe physical character of the adhesive, the adhesive characteristics ofthe particular material selected, and the method by which the adhesiveis applied.

The amount of hot melt adhesive applied also depends on the nature ofthe material, and the extent to which the hot melt penetrates into thepatch material. Typically, layer thickness of a hot melt adhesive layeris of the order of about 0.003 inch thick to about 0.030 inch thick,optionally about 0.005 inch thick to about 0.025 inch thick, and stillfurther optionally about 0.015 inch thick to about 0.020 inch thick, yetfurther optionally about 0.012 inch thick, all measured from the outersurface of the hot melt adhesive layer, prior to bonding to the shirtmaterial, to the interface of adhesive and fiber where multiple strandsof fiber are generally in contact with each other.

Where a pressure sensitive adhesive layer is used, the pressuresensitive adhesive layer is typically applied as a coating to the patchmaterial, and a carrier sheet is employed on the surface of the pressuresensitive layer until such time as the patch is applied to the shirt.

Still referring to FIG. 4, embroidery thread 48 passes through layer 42of the shirt material, layer 44 of the patch material, and layer 46 ofthe adhesive. By passing the embroidery thread through layer 42 of theshirt material, the shirt material can be used as a hooping material forpurposes of the embroidery process, whereby no auxiliary backing orhooping material need be employed in developing the embroidery indiciaon patch 18.

FIG. 5 illustrates a cross-section as in FIG. 4, but with the additionof a second layer 50 of adhesive between layer 46 of adhesive and layer42 of shirt material. In the embodiment of FIG. 5, there can bementioned, for example, a layer 46 of hot melt adhesive insurface-to-surface contact with the patch material layer 44 and a layer50 of contact adhesive overlying the layer 46 of hot melt adhesive andin contact with the shirt material. Prior to activation of the hot meltadhesive, the contact adhesive provides primary bonding between thepatch and the shirt material, by bonding to both the hot melt adhesiveand the shirt material. The hot melt adhesive is at that point bonded tothe patch material.

As an alternative, the adhesive layers can be reversed, such that thehot melt adhesive is bonded to the shirt material and the contactadhesive is bonded to the patch material.

When it is desired to develop a stronger or more permanent bond betweenthe patch and the shirt material by means of the hot melt adhesivecomponent, heat is applied to the outer surface of the patch,alternatively to the inner surface of the shirt, or both. Sufficientheat is driven through the respective layer of material, patch materialor shirt material, to activate the hot melt adhesive, whereupon the hotmelt adhesive becomes effective to bond the shirt material and the patchmaterial to each other.

FIGS. 1, 2, and 3 show the outline of the patch 18 as being a regulargeometric shape. FIGS. 1 and 2 show an oval shaped patch. FIG. 3 showsthe patch in the shape of the number “8”. While not further illustrated,the outline of the patch, namely the outer perimeter of the patch, canbe any outline desired by the designer of such patch. In that light, thepatch need not be a regular shape, or even a well-recognized shape.Indeed, the shape of the patch, as represented in its outer perimeter,and including any interior apertures 40, can take on any configurationimagined and applied by the designer of the patch. Thus, there can bementioned, for example the outline of any known object, or unknown andfanciful object. As known objects, there might be mentioned, for exampleand without limitation, plants, animals, mineral objects,representations of astrological images, flames, lights, manufacturedobjects, vehicles, and buildings. Fanciful images are, of course, notsubject to description until reduced to tangible representations of suchimages.

The patch can be any size which is compatible with fitting into an, orindustrial embroidery bed and which is compatible with bonding the patchto the e.g. garment substrate. Thus, the patch can be e.g. small such asthe name patch illustrated in FIG. 1, or can be large such as to cover alarge fraction of the front 12 or back 14 of the garment/shirt. Thepatch can be generally centrally-defined such as in a single centralizedelement; or can be rather dispersed such as in an array of raysemanating from a central location, or a non-central location. Multiplepatches can be used on a garment in one or more organized ornon-organized arrays. Thus, the design of the configuration of the patchand/or patch array is limited only by the imagination of the designer ofthe patch, and the space available on the substrate to receive thepatch, and is not limited spatially by the substance of the invention.

Exemplary of methods of developing garments of the invention, bearingembroidered such patches, is the following description of applying apatch to a shirt. A patch is cut from a sheet of patch material. Thepatch has an outer perimeter which defines an outer edge of the patch.Embroidery or other stitching can be applied in the outer edge region ofthe patch, if and as desired, after the patch has been cut out of thesheet of patch material to consolidate or maintain the integrity of theedge region of the patch.

In the alternative, embroidery or other stitching can be applied to thesheet of patch material before the patch is cut out, at or adjacent theprospective line of cutting. The edge of the stitching can be coincidentwith the edge of the cut-out patch.

In the alternative, the edge of the stitching can be e.g. slightlyinward of the outer edge of the cut-out patch.

In cutting out the patch, a laser cutter or heated cutting knife or diecutter can apply heat to the edge of the cut material, e.g. twill patchmaterial, during making the patch cut-out, sufficient to seal the patchmaterial near the threads while the knife or laser cutter is cutting outthe patch. Those skilled in the art can well develop suitable cuttingprocesses, including cutting temperatures, with reasonably nominaleffort, based on the specific parameters of the specific situation.

One or more layers of adhesive 46, 50 are applied to the patch materialeither before or after the patch is cut out of the patch sheet material.A single layer of adhesive can be used, either contact adhesive or hotmelt adhesive; or at least one layer of each. Additional layers ofadhesive can be used as desired.

A single layer of adhesive can be applied to either the patch or thepatch material, or to the shirt material. If applied to the shirtmaterial, the adhesive is optionally registered to the location wherethe patch will be applied. If applied to the patch, the adhesive can beapplied to the entirety of the inner surface 22 of the patch,alternatively to the sheet of patch material before the patch is cut outof the sheet of patch material. In some embodiments, the adhesive isapplied to the entirety of what will be, or is, the inner surface of thepatch, thereby maximizing the size of the potential surface by which thepatch can be bonded to the shirt material.

In some embodiments, a pressure sensitive adhesive is used which issufficiently aggressive to permanently affix the patch to the shirt. Insuch instance, the patch must be carefully positioned by the time theadhesive is in contact with the shirt material.

In other embodiments, a less aggressive adhesive is used, optionally incombination with a hot melt adhesive, whereby the less aggressivecontact adhesive accommodates at least limited repositioning the patchafter initial contact with the shirt material, and whereby the hot meltadhesive, if present, is activated after the location of the patch hasbeen confirmed, the contact adhesive being effective to hold the patchin place against modest forces, up to the time the hot melt adhesive isactivated.

Application of the embroidered indicia in the interior of the outersurface of the patch may be partially completed before the patch isapplied to the shirt material. However, at least a portion of theembroidery indicia remains uncreated at the time the patch is applied oraffixed or mounted to the shirt.

After the patch has been applied to the garment, and is being held inplace either with temporary strength of e.g. the contact adhesive, orwith permanent strength of either contact adhesive or a hot meltadhesive, the garment is hooped in an embroidery hoop, and desiredembroidery stitching is done. As illustrated in FIGS. 4 and 5, suchembroidery stitching extends through the patch, through the one or moreadhesive layers, and through the garment material. With the patchalready in place on the shirt, the embroidery process is continued untilsuch time as the desired amount of embroidery indicia has been added tothe patch.

The embroidery indicia applied to the patch with the patch mounted tothe garment, namely after-mounting embroidery, can be all of theembroidery which is applied to the patch, including edge embroiderywhich can be used to supplement the attachment of the patch to thegarment in the edge region.

The after-mounting embroidery can be all embroidery in the interiorregion of the patch, excluding edge embroidery stitching.

The after-mounting embroidery can be all embroidery in the interiorregion, and can extend into the edge region but can embroider less thanall of the edge region.

The after-mounting embroidery can cover all, or only a portion, of theinterior region of the patch.

The after-mounting embroidery can cover all, or substantially, all ofthe outer surface of the patch, including the entirety of the edgeregion.

The after-mounting embroidery can essentially cover all portions of thepatch which could conventionally be embroidered before the patch ismounted to the garment.

Since the garment material layer 42 can serve as the hooping material,no backing material need be used in order to secure, in the embroideryhoop or industrial embroidery bed, the material to be embroidered,though a backing material can be used as desired to provide additionalstiffness or other body to the garment layer 42 and/or the patch layerwhere the garment material and/or the patch material are relativelylighter weight materials, e.g. outside the conventional range of garmentmaterials and/or outside the range of patch materials. In general,though, no backing material is needed to support garment layer 42.

The embroidering on the patch after the patch has been secured to thegarment material typically serves to operate as a secondary affixationof the patch to the garment material.

However, where the extent of the embroidery on the patch is such as tocover a large fraction, e.g. at least 50%, optionally at least 70%, ofthe outer surface of the patch, the embroidery stitching can function asthe primary method of attaching the patch to the layer 42 of garmentmaterial. Accordingly, where a large fraction of the outer surface ofthe patch is to be embroidery stitched after the patch has been at leasttemporarily affixed to the garment material, a relatively lessaggressive adhesive composition can be used, as compared to where thestitching is extant over a relatively smaller fraction of the outersurface of the patch.

In the alternative, and still addressing the large fraction of thesurface area of the patch which is to be covered by embroiderystitching, a relatively lesser quantity of adhesive material can be usede.g. a thinner layer or a more disperse array of adhesive elements, oran intermediate quantity of an intermediately aggressive adhesive can beused.

In any event, the adhesion properties of the adhesive are matched to theneed to secure the patch to the garment material until a suitable degreeof attachment is developed by the embroidery stitching that a suitablelevel of attachment is supplied by the embroidery stitching.

Whatever the level of attachment of the patch to the garment material byembroidery stitching, upon completion of the embroidering on the patch,the level of securement of the patch to the garment material can beassessed, and additional adhesive strength activated as available inadhesive layer 46 and/or 50. Such assessment can be done globally forsetting up a run of multiple shirt/patch combinations, or can beassessed individually, garment by garment.

In some embodiments, sufficient heat is applied to the patch, eitherdirectly to the patch, or through garment layer 42 to the patch, tosecurely bond the patch to the garment before the after-mountingembroidery is begun. Accordingly, once the desired embroidering has beencompleted, the garment is removed from the embroidery hoop, whichcompletes process of the invention.

Where desired, additional heat can be applied, either to the entirepatch, or to selected portions of the patch, to further enhance bondingof the patch to the garment material.

Also where desired, additional conventional non-embroidery stitching canbe employed e.g. at the outer edge of the patch, through the patch,through the adhesive, and through the layer of garment material tofurther strengthen the attachment of the patch to the garment materialat the outer edge of the patch.

As used herein “permanent strength” or “permanent securement” of theadhesive means that a level of strength has been developed whereby thepatch stays in place in an environment of normal wearing use of theresulting garment. Such permanent strength can be developed byappropriately heating the hot melt adhesive in a conventionalT-shirt/garment press heater for about 5 seconds to about 30 seconds,optionally about 10 seconds to about 18 seconds, optionally about 12seconds. Such conventional T-shirt/garment press is useful for applyingconventional patches to garments using conventional hot melt adhesive.

While the above description has been expressed in terms of using anadhesive layer 46 to bond the patch to the garment, other means, such astemporary stitching, pins, spaced spots of adhesive can be employed tolightly secure the patch to the garment material until such time as theembroidered indicia provide a desired level of permanent securement ofthe patch to the garment.

For example, where the entire outer edge region is to be embroideredthrough the garment material, or where the entire outer surface of thepatch is to be embroidered through the garment material, only a lowlevel of temporary securement is required when the embroidery process isstarted, enough securement to keep the patch from moving until theembroidery stitching secures the patch permanently against undesiredamounts of movement. In such case, no adhesive need be used. Indeed, nosecurement material need be used which is of such nature as to be apermanent part of the finished garment. Thus, temporary pins, temporaryclips, temporary basting stitching can be employed; and can besubsequently removed after application of the embroidery indicia hasbeen completed, in which case no adhesive need be used, and no adhesiveneed be present in the finished garment. However, the embroiderystitching still extends through both the layer of patch material and thelayer of garment is material.

Where no adhesive is used, the permanent strength of attachment isprovided by the embroidered indicia which cover a large fraction of theouter surface of the patch. Where some areas of the edge region are notembroidered, or where adhesive is present but ineffective, supplementalattachment can be provided by additional stitching of the patch to thegarment material in those respective areas of the edge region which areso affected.

In some embodiments, the embroidery indicia extend across the boundaryof the patch and onto the outer surface of the garment such that aportion of the embroidered indicia is stitched directly to the garmentmaterial, and not through the patch. In such embodiments, part of theembroidered indicia overlie the patch, and part of the embroideredindicia directly overlie the garment material, outside the outerperimeter of the patch. Some of the embroidery threads, e.g. stitches,can bridge between the patch and the garment material. Especiallyoutside the outer perimeter of the patch, conventional embroiderybacking material can be used to support that portion of the embroideredgarment material which is not overlaid by the patch material.

In any of the embodiments of the invention, it is not necessary, and inmany embodiments, it is not desirable, to use any of theconventionally-used embroidery backing materials. Such embroiderybacking materials may be conventionally used, for example, to mount thepatch in an embroidery hoop. Such backing material may be used behindthe garment material where the embroidering is applied directly to thegarment substrate without intervening patch material. However, theabsence of backing material in the cross-sections of FIGS. 4 and 5 isintentional and use of backing material is not necessary toimplementation of the invention.

On the other hand, while use of backing material is exceptional in theinvention, backing material can beneficially be used in the invention incertain instances such as where the substrate material or the patchmaterial are especially flexible.

In any event, by extending the embroidery stitching through both thepatch and the shirt or other garment material, the patch cannot beremoved from the garment without damaging a substantial portion, or all,of the embroidered indicia on the patch, thus the appearance of thepatch.

Those skilled in the art will now see that certain modifications can beis made to the products and methods herein disclosed with respect to theillustrated embodiments, without departing from the spirit of theinstant invention. And while the invention has been described above withrespect to the preferred embodiments, it will be understood that theinvention is adapted to numerous rearrangements, modifications, andalterations, and all such arrangements, modifications, and alterationsare intended to be within the scope of the appended claims.

To the extent the following claims use means plus function language, itis not meant to include there, or in the instant specification, anythingnot structurally equivalent to what is shown in the embodimentsdisclosed in the specification.

1. In combination, a patch, and a garment to which said patch ismounted, said patch comprising a first outer surface facing away fromsaid garment, a first inner surface facing toward said garment, aperimeter which defines an outer edge of said patch, and an outer edgeregion disposed proximate the outer edge of said patch, said garmenthaving a second outer surface facing away from said garment, includingtoward said patch, and a second inner surface facing inwardly, toward abody of a wearer of said garment, said combination of said garment andsaid patch comprising embroidered indicia on the outer surface of saidpatch, threads defining said embroidered indicia extending through bothsaid patch and said garment.
 2. A combination as in claim 1, furthercomprising a layer of adhesive between said patch and said garment, saidthreads defining said embroidered indicia further extending through saidlayer of adhesive.
 3. A combination as in claim 2 wherein said layer ofadhesive comprises heat seal adhesive, bonding said patch to saidgarment.
 4. A combination as in claim 2 wherein said layer of adhesivecomprises contact adhesive bonding said patch to said garment.
 5. Acombination as in claim 2 wherein said layer of adhesive comprises afirst layer of heat seal adhesive and a second layer of contactadhesive.
 6. A combination as in claim 1 wherein the embroidered indiciais confined inwardly of the edge region.
 7. A combination as in claim 1wherein the embroidered indicia extends into the edge region.
 8. Acombination as in claim 1 wherein the embroidered indicia covers anentirety of the outer surface of said patch, including in the edgeregion.
 9. A combination as in claim 1 wherein the embroidered indiciais defined in part inwardly of the edge region, and in part in the edgeregion.
 10. A combination as in claim 1 wherein the embroidered indiciais predominantly informational in nature.
 11. A combination as in claim1 wherein the embroidered indicia is predominantly artistic in nature.12. A combination as in claim 1, further comprising stitching about theouter edge of said patch, as supplemental securement of the outer edgeof said patch to said garment.
 13. A combination as in claim 1, furthercomprising a cut-out aperture in said patch material, disposed inwardlyof the outer edge, and a second edge region about said cut-out aperture,wherein the embroidered indicia is displaced from the second edgeregion.
 14. A combination as in claim 1 wherein said patch is affixed tosaid garment that said patch cannot be removed from said garment withoutdamaging a substantial portion of the embroidered indicia on said patch.15. In combination, a patch, and a garment to which said patch ismounted, said patch comprising a first outer surface facing away fromsaid garment, a first inner surface facing toward said garment, aperimeter which defines an outer edge of said patch, and an outer edgeregion disposed proximate the outer edge of said patch, said garmenthaving a second outer surface facing away from said garment, includingtoward said patch, and a second inner surface facing inwardly, toward abody of a wearer of said garment, said combination of said garment andsaid patch comprising embroidered indicia on the outer surface of saidpatch, the embroidered indicia being configured in cooperation with saidpatch and said garment such that said patch cannot be removed from saidgarment without damaging a substantial portion of the embroideredindicia.
 16. A method of mounting a patch to a garment, the methodcomprising: (a) from a web of patch material, cutting out a patch havinga desired outline, the patch having first and second opposing surfaces,and an outer perimeter defining an outer edge of the patch, and acorresponding outer edge region proximate the outer edge; (b) subsequentto cutting out the patch, mounting the patch to the garment; (c) aftermounting the patch to the garment, embroidering indicia onto the patch,including extending embroidering threads through the patch material andthrough the garment.
 17. A method as in claim 16, further comprising,prior to mounting the patch to the garment, applying a layer of adhesivematerial to the patch so as to cover substantially the entirety of thefirst surface of the patch, and activating the adhesive as necessary inthe process of mounting the patch to the garment, whereby the adhesivematerial facilitates the mounting of the patch to the garment.
 18. Amethod as in claim 17 wherein the layer of adhesive material comprises alayer of hot melt adhesive, the method further comprising heating thehot melt adhesive in the process of mounting the patch to the garment,so as to activate the hot melt adhesive thereby to facilitate themounting of the patch to the garment, and wherein the extending of theembroidering threads through the patch material and through the garmentfurther comprises extending the embroidering threads through the layerof hot melt adhesive.
 19. A method as in claim 16, further comprisingconfining the embroidered indicia inwardly of the edge region.
 20. Amethod as in claim 16, including defining a first portion of theembroidered indicia inwardly of the edge region, and a second portion ofthe embroidered indicia in the edge region.
 21. A method as in claim 16,including defining the embroidered indicia over substantially theentirety of the outer surface of the patch, including in the edgeregion.
 22. A method as in claim 16 wherein the embroidered indicia ispredominantly informational in nature.
 23. A method as in claim 16wherein the embroidered indicia is predominantly artistic in nature. 24.A method as in claim 19, the patch further comprising a cut-out aperturein the patch material, disposed inwardly of the outer edge, and a secondedge region about the cut-out aperture, the method further comprisingconfining the embroidered indicia away from the second edge region. 25.A method as in claim 16 wherein the patch is so affixed to the garmentby the embroidered indicia thereon that the patch cannot be removed fromthe garment without damaging a substantial portion of the embroideredindicia on the patch, thus the appearance of the patch.
 26. A method ofcreating a garment bearing an embroidered patch, the patch having firstand second opposing surfaces, an outer perimeter defining an outer edge,and an edge region proximate the outer edge, the method comprising: (a)at least temporarily affixing the patch to the garment; (b) subsequentto at least temporarily affixing the patch to the garment, passingembroidery threads through both the patch and the garment in developingembroidered indicia on the patch.
 27. A method as in claim 26 including,prior to passing embroidery threads through both the patch and thegarment, the at least temporarily affixing of the patch to the garmentcomprising affixing the patch to the garment using an intervening layerof adhesive.
 28. A method as in claim 26 including, prior to passingembroidery threads through both the patch and the garment, the at leasttemporarily affixing of the patch to the garment comprising affixing thepatch to the garment using an intervening layer of hot melt adhesive.29. A method as in claim 26, further comprising confining theembroidered indicia inwardly of the edge region.
 30. A method as inclaim 26, including defining a first portion of the embroidered indiciainwardly of the edge region, and a second portion of the embroideredindicia in the edge region.
 31. A method as in claim 26, includingdefining the embroidered indicia over substantially the entirety of theouter surface of the patch, including in the edge region.
 32. A methodas in claim 26, comprising defining embroidered indicia which ispredominantly informational in nature.
 33. A method as in claim 26,comprising defining embroidered indicia which is predominantly artisticin nature.
 34. A method as in claim 26 wherein the patch is so securedto the garment that the patch cannot be removed from the garment withoutdamaging a substantial portion of the embroidered indicia on the patch.